Method of attaching a female element to a panel

ABSTRACT

A method of attaching a female element having an annular riveting portion to a panel and the installation apparatus. The method includes driving a punch through the female element into a panel supported on a die member forming an unsupported cone-shaped panel portion in the cavity of the die member. The punch includes an axially extending piercing end which pierces a small opening in the cone-shaped panel portion and an arcuate drawing portion which is driven against and through the panel opening, enlarging the panel opening. The annular riveting portion of the female element is then driven into the cone-shaped panel portion and through the panel opening, drawing the panel portion into a tubular shape engaging the external surface of the riveting portion. Finally, the riveting portion is driven against a center post of the die member, radially outwardly deforming the free end of the riveting portion and forming a mechanical interlock with the tubular panel portion. In the preferred embodiment of the die member, the center post includes an axial bore and is spring biased through an opening in the bottom of the die cavity to receive the slug pierced from the panel by the punch. The center post is then resiliently biased downwardly to mate with the die cavity during radial deformation of the riveting portion of the female element.

RELATED APPLICATIONS

This application is a continuation-in-part application of co-pendingapplication Ser. No. 069,804, filed Aug. 17, 1987, now U.S. Pat. No.4,810,143, which application was a divisional application of copendingapplication Ser. No. 869,507 filed June 2, 1986, now U.S. Pat. No.4,700,470, which application was a divisional application of Ser. No.657,570 filed Oct. 4, 1984, now U.S. Pat. No. 4,610,072, whichapplication was a continuation-in-part application of Ser. No. 563,833,filed Dec. 21, 1983, now U.S. Pat. No. 4,555,838, which application wasa continuation-in-part application of Ser. No. 504,074, filed June 14,1983, now U.S. Pat. No. 4,543,701 and Ser. No. 485,099, filed Mar. 28,1983, now U.S. Pat. No. 4,459,073, Ser. No. 504,074 was a continuationof Ser. No. 229,274 filed Jan. 28, 1981, abandoned, and Ser. No. 485,099was a divisional application of Ser. No. 229,274 filed Jan. 28, 1981,abandoned. Ser. No. 229,274 claims priority to an application filed inthe Federal Republic of Germany, No. 3003908 filed Feb. 2, 1980.

FIELD OF THE INVENTION

The present invention relates to installation apparatus and methods ofattaching a female element, particularly female fastener elements suchas nuts, to a panel, wherein the panel is pierced and the female elementis installed in the pierced panel opening in a continuous operation.

The prior art includes self-piercing female elements, including nuts,which may also be simultaneously clinched to secure the nut in thepierced panel opening, such as disclosed in U.S. Pat. Nos. 3,299,500 and3,314,138 assigned to the assignee of the instant application. The priorart also includes a number of self-riveting nuts including nuts havingan annular skirt or barrel portion wherein the free end of the barrelportion is deformed radially outwardly in a die member to form amechanical interlock with the panel, see for example U.S. Pat. Nos.3,938,239 and 4,018,257. The self-riveting nuts disclosed in suchpatents are, however, secured to a panel having a prepierced panelopening requiring two separate operations. Such methods also requirevery precise centering of the nut relative to the prepierced panelopening, wherein a spring biased pin is received through the panelopening and the nut is centered on the pin prior to installation. U.S.Pat. No. 3,926,236, which is also assigned to the assignee of theinstant application, discloses a method of attaching a nut wherein thepanel is pierced by a punch which extends through the nut bore to pierceand secure the nut in a continuous operation, however, the fastener isnot a riveting-type fastener having a barrel portion extending throughthe pierced panel opening. The prior art also includes a number ofpatents which disclose methods of attaching closures to a container suchas a tag ring in a continuous operation, such as U.S. Pat. No.3,800,401.

This application and the above-identified related patents andapplications disclose methods and apparatus for attaching male andfemale elements to a panel, such as nuts and bolts, in a continuousoperation. The preferred methods of installation do not requireprepiercing of the panel, although the fasteners may be installed in aprepierced panel opening. Certain difficulties have, however, beenexperienced in installing a female element in a panel, particularlywhere the barrel portion of the female element is used to pierce thepanel opening. The method of attaching a female element to a panel ofthis invention and installation apparatus is intended to solve theproblems associated with the prior art and the previously disclosedmethods and apparatus.

SUMMARY OF THE INVENTION

The method of attaching a female element to a panel of this inventionsolves the problems of installing a nut-type fastener in a continuousoperation experienced with the methods previously disclosed in theabove-identified related patent and permits installation of a nut-typefastener in a flush mounting, wherein the body portion of the fasteneris flush with the panel. The female element includes a body portionhaving a bore therethrough and an integral barrel portion having a freeopen end coaxially aligned with the body portion. The method of thisinvention includes locating and aligning the female element opposite apanel preferably supported in fixed relation on a die member having aconcave die cavity generally coaxially aligned with the female elementwith the barrel portion free end facing the panel. The free end of apunch is then driven through the female element into engagement with thepanel. The free end of the punch which engages the panel includes anaxially extending piercing end having a diameter which is substantiallyless than the internal diameter of the barrel portion followed by anenlarged convex drawing portion. As the punch is driven into the panel,it forms an unsupported generally cone-shaped panel portion into the diecavity. The piercing end of the punch then pierces a slug from generallythe center of the unsupported cone-shaped panel portion, forming thesmall pierced panel opening. Finally, the drawing portion of the punchis driven against the panel, enlarging the panel opening and furtherdriving the cone-shaped panel portion into the die cavity. The barrelportion of the female element is then driven into the cone-shaped panelportion and through the pierced panel opening into the die cavity,drawing the panel portion into a tubular shape. Finally, the barrelportion free end is deformed radially in the die cavity to form amechanical interlock with the tubular panel portion.

Where a flush mounting of the female element in the panel is desired,the body portion of the female element is driven into the developingcone-shaped panel portion until it is flush with the adjacent surface ofthe panel. In the most preferred embodiment of the flush mountedassembly, the body portion includes a shoulder adjacent the barrelportion which faces the panel. The method then includes driving theshoulder of the female element into the panel portion which entraps thepanel portion between the shoulder and the radially deformed barrelportion free end forming a very secure mechanical interlock whichprevents withdrawal of the female element from the assembly. As will beunderstood, the formation of the panel adjacent the pierced panelopening is particularly important to the formation of a secure assembly.In the most preferred method of this invention, the free end of thebarrel portion is biased against the cone-shaped panel portion duringpiercing of the panel under a predetermined load and the load ismaintained as the punch is driven through the panel opening.

The preferred die member includes a separate projecting center postwhich is surrounded by the die cavity. The die post has an axial borewhich is coaxially aligned with the piercing end of the punch. In themost preferred embodiment, the die post is spring biased toward thepanel to receive the slug pierced from the panel, avoiding inadvertentejection of the panel slug into the die cavity. As the panel is furtherdeformed into the die cavity by the barrel portion of the nut, the diepost is biased into the die cavity to receive the free end of the barrelportion of the nut to deform the barrel portion radially, as described.The die member includes a stop which generally aligns a concave radialdie portion on the die post with the bottom surface of the die cavity,radially deforming the free end of the barrel portion into a preferred uor hook shape which receives the tubular panel portion. In the mostpreferred embodiment, the die surface of the post is located just abovethe mating surface of the die cavity to avoid locking.

The installation head of this invention, which receives the femaleelements for installation in a panel, includes a first passage whichreceives the female elements and a second plunger passage whichcommunicates with the first passage. A punch reciprocates in the plungerpassage having an outer surface and a free end. The punch free endpreferably includes an integral generally cylindrical axially extendingpiercing portion and a transitional generally arcuate drawing surfacewhich extends radially outwardly from the piercing portion and blendssmoothly into the body portion of the punch. A plunger is telescopicallydisposed around the punch having a driving surface at its free end. Asdescribed, the punch free end is telescopically received through thefemale element bore and riveting portion to engage the panel. Theactuating means of the installation head first drives the free end ofthe punch into piercing engagement with the panel, forming thecone-shaped portion, piercing a slug from the panel to form a piercedpanel opening and driving the drawing surface against the panel, asdescribed above. The plunger is then driven against the body portion ofthe female element, driving the riveting portion against the panel andthrough the pierced panel opening to install the panel by the methoddescribed.

The method and installation apparatus of this invention combines theadvantages of the methods of attaching a female element to a panel andapparatus described in the above-identified related patents. First, thepiercing of the panel with a punch, alone, rather than the punch incombination with the die button, eliminates the problem of forming acrescent-shaped slug which occasionally hung up in the die assembly.Further, the preformation of the panel into an unsupported generallycone-shaped portion accurately aligns the assembly prior to piercing.The piercing of a relatively small slug permits flush mounting of thefemale element in the panel. The formation of a tubular shape providescolumn strength preventing withdrawal of the female element from theassembly. Finally, the method of this invention permits installation offemale elements in a panel on a production basis, such as required forautomotive installations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side partially cross-sectioned view of an installationapparatus ready for installing a female element;

FIG. 2 is a side partially cross-sectioned view similar to FIG. 1 duringthe installation sequence;

FIG. 3 is an exploded partially cross-sectioned view of the die assemblyshown in the lower portion of FIG. 1;

FIG. 4 is a side partially cross-sectioned view of a portion of FIG. 2;

FIG. 5 is an enlarged view of FIG. 4;

FIGS. 6 to 13 are partially cross-sectioned side elevations illustratingthe sequence of installation of the female element using theinstallation apparatus shown in FIGS. 1 and 2; and

FIG. 14 is a partially cross-sectioned side elevation similar to FIGS. 6to 12, following installation of the female element in a panel.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The method of installing a female element and installation apparatus ofthis invention is particularly, although not exclusively, adapted fordie press installations, such as used by the automotive and applianceindustries to form sheet metal. The method and apparatus of thisinvention is also particularly suitable for mass production, wherein afemale element or a plurality of female elements are installed with eachstroke of a die press in a continuous operation running over extendedperiods of time. As stated above, problems developed in installingfemale elements by the methods described in the above-referenced relatedpatents in mass production. These problems resulted primarily because ofthe requirement for close tolerances and very accurate alignment of thebarrel portion of the female element and the die member which cooperatedto pierce an opening in the panel. In mass production, where closetolerances are difficult to maintain, crescent-shaped slugs weresometimes formed in addition to the intended circular slug, which couldjam the installation apparatus. Further, a commercial method was notavailable for removing the panel slug.

The method and apparatus of this invention is particularly, although notexclusively adapted for flush mounting the female element in a panel,wherein the body portion of the nut is driven into the panel flush withthe adjacent panel portion. Where the female element is a nut-typefastener having internal threads, the nut may then be used to attach thepanel to a mating panel or structural element, eliminating therequirement for an embossment. The nut and panel assembly isparticularly strong in resisting angular or perpendicular shear in amating panel assembly or pull-out because of the column strengthprovided by the tubular shape drawn in the panel, in combination withthe U or hook-shaped channel formed in the barrel portion of thefastener.

Although the female element may be attached to various types of platesor panels, the method and apparatus of this invention is particularlysuited for installing a female element in a plastically deformable metalpanel, such as used by the automotive and appliance industries forstructural components. For example, the female element may be attachedto relatively thin panels having a thickness of approximately 0.025inches to relatively thick panels having a thickness of about 0.10inches or greater. The dimensions of the female element will, of course,depend upon the desired thread diameter, the thickness of the panel andthe particular application. A female element, such as a self-rivetingnut, may be formed of medium carbon steels, and installed in a widevariety of metal panels, including low and medium carbon steels.

Reference should also be made to the above-identified related patentsand applications incorporated herein by reference which disclose furtherdetails of installations and installation apparatus. As will beunderstood, the method and installation apparatus of this invention isan improvement of the methods and apparatus previously described adaptedfor particular applications as disclosed herein.

Referring now to the drawings, particularly FIGS. 1 and 2 whichillustrate one embodiment of an installation apparatus including a headassembly 20 and a die assembly 22. The head assembly 20 may be attachedto an upper die shoe 24 of a die press and the die assembly 22 may beattached to a lower die shoe 26. As will be understood, "upper" and"lower" are relative terms assuming that the female elements areattached in a downstroke of the press. The method of this invention isnot, however, limited to a system where the self-attaching elements areinstalled in a downward direction. The die assembly may for example belocated in the upper die shoe and the head assembly may be located inthe lower die shoe for upward installation of the self-attachingelements. The disclosed embodiment of the installation apparatus isparticularly suitable for installing self-attaching elements in a diepress such as used by the automotive and appliance industries to formthe panel or plate in a contoured configuration, however, the method andinstallation apparatus of this invention are not limited to suchapplications.

In the disclosed embodiment of the installation apparatus, the headassembly 20 is attached to the upper die shoe 24 by bolts, not shown andhardened back-up plate 28 is provided as a load bearing member. The headassembly 20 is attached to the back-up plate 28 by a plurality of bolts30 and alignment dowels 32 may be used to accurately position theinstallation head and back-up plate on the upper die shoe. Thestructural components of the housing assembly include the base housing34, which is attached by bolts 30 to the back-up plate, the nose housing36 and the nose piece 38 having an opening 39 for installation of thefemale elements. The nose piece 38 may be attached to the nose housing36 by screws (not shown) or other suitable means.

As shown by comparing FIGS. 1 and 2, the nose housing 36 and nose piece39 move relative to the base housing 34 during operation of theinstallation apparatus. This relative movement is guided by cylindricalguide shank 40 having an offset bore 42. Guide shank 40 is attached tothe nose housing 36 by master bolt 44 and a coil spring 46 is receivedin the bore 42. The upper portion of the coil spring 46 is receivedthrough openings 48 and 50 in the back-up plate 28 and upper die shoe24, respectively, and the upper end of the coil spring 46 is received inan alignment bore 52 in the upper die shoe. The powerful coil spring 46thus urges the nose housing 36 away from the base housing 34 to the"open" position shown in FIG. 1. The nose housing 36 is retained on thebase housing 34 by housing retaining pin 54 which is received through abore 56 in the base housing 34 to engage a shoulder 58 on the guideshank 40. The end of the retaining pin 54 is received in a keyway slot60 in the outer surface of the guide shank 40 to guide the relativemovement of the assembly. A retainer clip 62, which is attached to thebase housing 34 by a screw 64, prevents inadvertent removal of thehousing retaining pin 54. An orienting bolt 66 accurately aligns theguide shank 40 on the nose housing 36.

In the disclosed embodiment, the nose housing 36 includes anantifriction bushing 68, such as a bronze bushing, which is received ina bore 70 in the base housing 34 and a stop block 72 retains the bushing68 and limits relative upward movement of the nose member 36.

The operational components of the housing assembly 20 include a punch 74and a plunger 76. The punch 74 includes an upper portion 77 which isattached to the back-up plate 28 by a screw 78. The punch 74 is thusfixed relative to the base housing 34. The punch 74 further includes alower portion 80, which is attached to the upper portion by a threadedshank 82 on the upper portion 77. As described more fully hereinbelow,the free end of the punch includes a piercing portion 86.

The plunger 76 may also be formed of two components, including an upperportion 88 having a piston head 90 and a lower portion 92 having a freedriving end 94. In the disclosed embodiment, the upper end portion 88 ofthe plunger 76 is attached to the lower end portion 92 by a conventionalthreaded connection 96. As will be understood from the followingdescription, the piercing portion 86 of the punch 74 is subject to wearand therefore must be periodically replaced during use. This can easilybe accomplished in the disclosed embodiment of the invention by firstthreadably removing the lower portion 92 of the plunger, which providesaccess to the lower portion 80 of the punch. The lower portion 80 of thepunch may then be threadably disconnected from the upper portion 77 andreplaced.

As shown, the plunger 76 includes a configured axial bore 98 and theplunger is telescopically received on the punch 74. Further, the pistonhead 90 of the plunger 76 is free to reciprocate in the cylindrical bore97 in the base housing 34. Thus, as described more fully hereinbelow,the plunger 76 will move relative to the base housing 34 as the nosehousing 36 is "closed" relative to the base housing 34, as shown inphantom at 90A in FIG. 1. A pneumatic fitting 100 is attached to theback-up plate 28 which communicates with bore 97 through port 102. Thepneumatic fitting 100 is attached to a source of line air pressure 104maintaining a predetermined pressure in bore 97. When the piston head 90moves past the enlarged portion 106 of the punch 74, air is receivedthrough the axial bore 98 in the plunger into cross port 108 in thelower end of the punch, periodically ejecting air through the axial bore110 through the piercing end 86 of the punch to remove a slug piercedfrom the panel, as described hereinbelow. External and internal O-ringseals 112 and 114, respectively, are provided in the piston head 90.

As described, the installation head 20 is particularly adapted forattaching self-riveting elements 116 which are received through apassage 118 in the nose housing 36. The self-riveting elements 116 aredelivered to the passage 118 by a guide chute 120. The guide chute 120is attached to the nose housing 36 and nose piece 38 by chute attachingblock 122 as described in the above-identified related patents.

In the disclosed embodiment, the head assembly includes a conventionalproximity sensor 124 which is retained in the assembly by retainer 126and the proximity sensor is connected to the control means for thesystem by line 128. The proximity sensor determines whether aself-riveting element 116 is in the installation ready position, asshown in FIG. 1. If a self-attaching element is not in the readyposition, the press will not cycle thereby avoiding a double hitcondition.

FIGS. 1, 3 and 5 best illustrate the die assembly 22. The die assemblyincludes a die member 130 having a cup-shaped die opening 132 and acenter die post 134. The die post 134 is received through a central oraxial opening 136 in the die member 130, and the die post and opening136 include mating conical surfaces 138, 139 (see FIG. 3) which limitupward movement of the die post. The die post is spring biased upwardlyby coil springs 140 each having pins 142 resiliently biased against aradial shoulder 144 of the die post 134. The shoulder 144 also limitsdownward movement of the die post. When the die post is biaseddownwardly during installation of the self-riveting elements, theshoulder 144 engages ring 146. Ring 146 is attached to the die member130 by bolts 148 and the die member 130 is secured within an opening 150in doe bittpm retaomer 149 by stop block 152 and bolt 154. The diebutton retainer is attached to the lower die shoe 26 by bolts, notshown. As described more fully hereinbelow, the center post 134 includesan axial bore 156 which receives the panel slugs and the lower die shoeincludes a coaxially aligned bore 158. In the disclosed embodiment, thelower die shoe includes a back-up ring 160 having a bore 162 coaxiallyaligned with the bores 156 and 158.

Reference is now made specifically to FIGS. 3 to 5 which illustratedetails of the preferred embodiment of the die set and assembly of thisinvention. The self-riveting elements 116 include a body portion 164having a flat end 168 for engagement by the flat driving end 94 of theplunger 76. It will be understood that the end 94 of the plunger may beotherwise configured to mate with the end 168 of the self-rivetingelements. The body portion 164 of the self-riveting element includes anaxial bore 170, which in the disclosed embodiment is internallythreaded, such that the self-riveting element serves as a nut-typefastener when attached to the panel, as described hereinbelow. Theself-riveting elements further include an annular riveting or barrelportion 172 which is preferably integral with the body portion 164 andcoaxially aligned with the bore 170. The free end of the annularriveting portion preferably includes an arcuate external surface 174, asbest shown in FIG. 5, and a conical chamfer surface 176 which joins thearcuate surface 174 with the internal surface 178 of the annularriveting portion. The diameter of the external surface 180 of the barrelportion is preferably less than the diameter of the external surface 182of the body portion 164 defining a radial arcuate shoulder 184 on thebody portion, which is driven into the panel, as described below.

As best shown in FIG. 5, the piercing end 86 of the lower portion 80 ofthe punch 74 is preferably cylindrical having a flat end 186. Thecylindrical piercing portion 86 is integral with the lower portion 80 ofthe punch 74 through a smooth arcuate convex drawing surface 188. Theupper surface of the die post 134 includes a concave arcuate die surface190 spaced from the free end. The free end of the die post includes aconical exterior surface 192, a radial end surface 194 and a chamfer 196in the opening to the axial bore 156.

The die member 130 includes a panel supporting surface 200 whichsurrounds the cup-shaped die opening 132. The outer wall of the dieopening includes a conical surface 202 which blends into the panelsupporting surface 200 through a smooth arcuate surface 204. In thedisclosed embodiment, the bottom surface 206 of the die cavity 132 isconcave, including a generally conical upper surface 208 and ahemispherical surface 210 which generally mates with the concave diesurface 190 of the die post 134 during radial deformation of the annularbarrel or riveting portion 172 of the self-riveting element 116, asdescribed below.

Further details of the disclosed embodiment of the die assembly arefound in FIG. 3. The die post 134 includes a tubular end portion 212which is closely received in the cylindrical opening 214 of the ring 146(see also FIG. 1). The die post also includes a cylindrical externalsurface 216 which is closely received in the upper portion of the diebore 136 and a lower cylindrical surface 218 which is received in thelower cylindrical portion of the die bore. The pins 142 each include ahead portion 220 which is biased against the shoulder 144 of the diepost. The disclosed embodiment includes 3 pins 142 which are received incylindrical channels 222 and three bolts 148 are received in bores 224in the retainer ring 146 and threaded bores 226 in the die member 130.As shown in FIG. 1, the exterior surface 182 of the body portion of thedisclosed embodiments of the self-riveting elements is hexagonal,preventing rotation of the self-riveting element in the panel followinginstallation. The outer surface 202 of the die cavity 132 of die member130 may also be configured to prevent rotation of the self-attachingelements in the panel. For example, the exterior surface 202 of the diecavity may be hexagonal, defining a radial lip 227, as shown in FIG. 5.

Having described the elements of the installation apparatus and die set,including the self-attaching elements, it is now possible to describethe operation of the installation apparatus and the method of attachingthe self-riveting elements of this invention. A female element 116 isfirst aligned opposite a panel 250 with the free end of the annularriveting or barrel portion 172 facing the panel and the barrel portioncoaxially aligned with the die post 134 of the die assembly 22 in theinstallation ready position as shown in FIG. 1. The flat end 94 of theplunger 76 is coaxially aligned with the flat end 168 of the femaleelement body portion and the punch 74 is coaxially aligned with the bore170. In a conventional installation of the type disclosed herein,wherein the head 20 is attached to one die platen 24 and the dieassembly 22 is attached to a second die platen 26, the method of thisinvention is performed simply by relatively closing the die press. Asthe die press is closed, the nose piece 38 engages the panel 250 whichis then fixed on the panel supporting surface 200, as shown in FIG. 2.Further closing of the die press, causes relative movement of the basehousing 34 of the installation head 20 toward the die assembly 22,causing the nose housing 36 to move toward the base housing 34,relatively "closing" the installation head 20. Because the punch 74 isfixed relative to the base housing 34, the punch is moved telescopicallythrough the female element bore 170 and the annular barrel portion 172to engage the panel as shown in FIGS. 4 and 5. The free end 94 of theplunger engages the end 168 of the body portion of the female elementand moves the female element downwardly to engage the panel. However,the plunger is not fixed relative to the base housing 34. As theinstallation head 20 is relatively "closed", the piston head 90 of theplunger 76 is biased upwardly into bore 96 against the pneumaticpressure in line 102 and bore 97. The arcuate surface 174 of the barrelportion 172 of the female element is therefore biased against the panelunder a predetermined load based upon the pneumatic pressure in bore 97.Continued movement of the installation head 20 toward the die assembly22 drives the piercing end 86 of the punch against the unsupported panelportion 252 overlying the cup-shaped die cavity 132. As shown in FIG. 4,the main panel portion 250 is fixed between the nose piece 38 and thepanel supporting surface 200 of the die member 130, however, the panelportion 252 overlying the die cavity 132 is unsupported because the diepost 134 is telescopically movable downwardly into the die cavityagainst the relatively weak force of coil springs 140. As the punch isdriven downwardly against the panel, the panel portion 252 is firstdriven into the die cavity 132 forming an unsupported generallycone-shaped panel portion 252 in the die cavity as shown in FIGS. 2, 4and 5. The relatively sharp edge 228 of the piercing portion 86 of thepunch 74 then pierces a circular slug 230 from the center of the conicalpanel portion 252, forming a circular opening 254, as shown in FIG. 6.

The piston head 90 of the plunger 76 is then located above the enlargedportion 106 of the punch 74, as shown in phantom at 90A in FIG. 1 andair is allowed to pass through the bore 98 in the plunger to inlet 108in the punch, ejecting air through axial passage 110 through thepiercing end 86 of the punch, as described above. The air pressure thenejects the slug 230 into the bore 156 of the die post 134 when the postis engaging the panel, as shown in FIG. 6. In the preferred method ofthis invention, wherein the female element is mounted flush in thepanel, the slug 230 is preferably relatively small. As best shown inFIG. 6, the free radial end 194 of the die post 134 is maintained incontact with the panel portion 252, assuring that the panel slug 230 isinjected into the bore 156, and not into the die cavity 132, which wouldinterfere with the installation of the female element. Followingpiercing of the panel, as shown in FIG. 6, the arcuate drawing surface188 of the punch 74 is driven against the panel portion adjacent theopening 254, further drawing the panel into the die cavity 132 andenlarging the panel opening. As shown in FIG. 7, the drawing surface 188is then driven, at least partially in the disclosed embodiment throughthe pierced panel opening 254, enlarging the panel opening and drivingthe conical panel portion 252 into the die cavity 132.

The piston head 90 then bottoms against back-up plate 28, as shown inFIG. 2. The plunger 76 is then "fixed" relative to the base housing 34,however, the stop block 72 has not yet bottomed against base housing 34.Thus, the nose housing 36 continues to move toward the base housing 34as the die press is closed, driving the free end 94 of the plungeragainst the end 168 of the body portion of the female element 116. Thefree arcuate end 174 of the barrel portion 172 of the female element 116is then driven into the panel portion as shown in FIG. 8, furtherenlarging the opening 254 in the panel portion 252. The barrel portionis then driven through the panel opening, as shown in FIG. 9,plastically deforming the panel portion into a tubular configuration252a.

As shown in FIG. 10, the free end of the annular barrel portion 172 isthen received through the tubular panel portion 252a and the chamferedsurface 176 is received against the concave die surface 190 of the diepost to deform the barrel portion radially outwardly, as describedhereinbelow. It will be noted by comparing FIGS. 6 to 10 that the diepost is continually urged downwardly first by the panel portion, asshown in FIGS. 6 to 8, and then by the chamfered surface 176 of thebarrel portion, as shown in FIGS. 9 and 10, until the shoulder 144 ofthe die post engages the upper surface of the retainer ring 146 (seeFIG. 1). When the die post bottoms against the retainer ring, theconcave die surface 190 is preferably located a few thousandths of aninch above the mating hemispherical concave die surface 210 to avoid anybinding of the free end of the annular barrel portion as it is deformedradially outwardly, as now described.

The free end of the barrel portion is then driven against the concavesurface 190 of the die post 134, as shown in FIGS. 11 and 12, thickeningthe free end, as shown at 174a in FIG. 12, and beginning the radialoutward deformation of the barrel portion. The arcuate shoulder 184 ofthe body portion 164 is then driven into the tubular panel portion 252a,driving the panel portion toward the free end 174a of the barrel portionand the free end of the barrel portion is simultaneously driven radiallyoutwardly into the mating concave surface 206 of the die cavity, asshown in FIG. 13.

Finally, the free end 174a of the barrel portion 172 of the femaleelement is deformed into a U or hook-shaped channel 174b and the panelportion 252b is driven into the hook-shaped portion and entrapped by thebody portion shoulder 184 as shown in FIG. 14. The end surface 168 ofthe body portion 164 of the female element is now flush with the mainportion 250 of the panel which is an important advantage of the methodof installation of this invention. Thus, the female element and panelassembly may be used to clamp the panel 250 to another panel orstructural element without embossing or recessing the female element.For example, a second panel or structural member may be clamped to panel250, wherein the second panel overlies the end surface 168 of the femaleelement. It should further be noted that the tubular panel portion 252bprovides column and shear strength for the assembly. That is, if a boltthreaded into female thread 170, it will exert a force upwardly in FIG.14 as the bolt is tightened. The hook shaped channel portion 174b willthen be driven into tighter engagement with the tubular panel portion252b and the column provided by the tubular panel portion will improvethe strength of the assembly.

It will now be understood that the method of this invention is performedin a continuous operation and the method and apparatus of this inventionare particularly suited for mass production, wherein female elements areinstalled in the panel with each stroke of the die press. Aftercompleting the installation, the die press is opened, as shown in FIG.1, and the spring 46 extends the nose housing 36 to the position shownin FIG. 1. As described in the above-referenced related applications, afeed mechanism (not shown) continuously feeds female elements (116) tothe ready position, preferably as the housing assembly 20 is opened,such that a female element is ready for installation as soon as thepress is fully opened.

Briefly, the method of this invention then includes driving the piercingend 86 of the punch 74 through the female element body portion bore 170and the annular barrel portion 172 into engagement with the panel 250.The punch then performs the following operations, generally in sequence:first, the punch free end drives the unsupported panel portion 252 intothe die cavity 132, forming a generally cone-shaped panel portion 252 inthe die cavity, as shown in FIGS. 4 and 5. The punch piercing end 86then pierces a slug 230 from the center of the cone-shaped panel portion252, forming a panel opening 254. The drawing surface 188 is then driveninto the panel, adjacent the panel opening, enlarging the panel openingand further driving the panel portion into the die cavity. The drawingsurface 188 may be driven at least partially through the panel opening254, further enlarging the panel opening and driving the panel portioninto the die cavity. The free end 174 of the female element barrelportion 172 is then driven into the cone-shaped panel portion 252 andthrough the panel opening, reforming the panel portion into a tubularshape 252a, as shown in FIG. 9. Finally, the free end of the barrelportion 172 is driven against the concave die surface 190 of the diepost 134 radially outwardly into engagement with the generally matingconcave surface 210 of the die cavity, forming a U or hook-shaped ringchannel 174b on the barrel portion and forming a mechanical interlockwith the panel portion 252b, as shown in FIG. 14. In the most preferredembodiment of the method of this invention, the shoulder 184 of the bodyportion is also driven into the panel portion 252b, entrapping the panelportion and mounting the upper surface 168 of the body portion flushwith the main portion 250 of the panel.

As will now be understood, the deformation of the panel as described isvery important to forming a secure mechanical interlock between thebarrel portion 172 of the female element 116 and the panel portion 252b,as shown in FIG. 14. In the method of this invention, the deformation ofthe panel is very accurately controlled. Although the panel portion 252is unsupported by the die assembly during piercing, the panel portion iscontrolled at all times. First, the free end 174 of the barrel portionis biased against the panel under a predetermined load which ismaintained during piercing, controlling the formation of the cone-shapedpanel portion 252a, as the panel is pierced. The panel is then receivedagainst the arcuate drawing surface 188, as shown in FIG. 6, forming asecond ring contact with the barrel portion. The free end of the barrelportion is then driven into the panel portion 252, maintaining controlof the panel deformation as the panel is drawn into a tubular shape.

As will be understood, various modifications may be made to the methodand installation apparatus of this invention within the purview of theappended claims. As described above, the die post 134 is preferablyspring biased upwardly to maintain the free end 194 in contact with thepanel portion 252 to assure that the relatively small slug 230 isejected into the die post bore 156. As will be understood, however, themeans biasing the die post upwardly is not limited to a spring or aplurality of springs. The die post may be biased upwardly by pneumaticpressure, for example, or a resilient pad. As shown, the internaldiameter of the inner surface 178 of the annular barrel portion 172 isover twice the diameter of the panel slug 230, providing sufficientmetal for a flush mounting of the female element in the panel as shownin FIG. 14 and providing certain of the advantages of the method of thisinvention, including the column and shear strength provided by thetubular portion 252b. It will be understood, however, that the method ofthis invention may also be used where the diameter of the slug is morenearly equal to the internal diameter of the barrel portion 172.Further, the details of the commercial embodiment of an installationhead 20 and die assembly 22 are disclosed herein as the best mode knownto the Applicant for performing the method of this invention. It will beunderstood, however, that the method of this invention is not limited tothe disclosed apparatus, particularly the detailed constructiondisclosed, and the improvements in the installation apparatus are notlimited to the methods performed by the installation apparatus.

I claim:
 1. A method of attaching a female element to a plasticallydeformable panel, said female element including a body portion having abore therethrough and an integral barrel portion generally concentricwith said body portion bore and communicating therewith, said barrelportion having inner and outer surfaces and a free open end, said methodcomprising the following performed in a continuous operation:(a)locating and aligning said female element opposite a panel supported ona die member having a concave die cavity generally coaxially alignedwith said female element and said barrel portion free end facing saidpanel; (b) driving a free end of a punch through said female elementbody portion bore and said annular barrel portion into engagement withsaid panel, said punch free end including an axially extending piercingend having a diameter substantially less than the internal diameter ofsaid barrel portion internal surface followed by an enlarged convexdrawing portion to perform the following method steps generally insequence:(1) said punch free end driving said panel into said die cavityforming an unsupported generally cone-shaped panel portion in said diecavity; (2) said punch piercing end piercing a slug from generally thecenter of said unsupported generally cone-shaped panel portion forming apierced panel opening; (3) driving said punch drawing surface againstsaid panel portion; (c) driving said female element barrel portion freeend into said cone-shaped panel portion and through said pierced panelopening into said die cavity, said barrel portion external surfacedrawing said panel portion into a tubular shape; and (d) plasticallydeforming said barrel portion free end radially outwardly in said diecavity to form a mechanical interlock with said panel portion.
 2. Themethod of attaching a female element to a panel as defined in claim 1,wherein said barrel portion free end is biased against said cone-shapedpanel portion spaced radially from said punch under a predetermined loadprior to piercing said panel portion and maintaining said predeterminedload as said punch is driven through said panel opening.
 3. The methodof attaching a female element to a panel as defined in claim 1,including driving said female element body portion into the developingtubular panel portion as said barrel portion free end is deformedradially outwardly forming a flush mounted female element and panelassembly.
 4. The method of attaching a female element to a panel asdefined in claim 3, characterized in that said body portion includes ashoulder adjacent said barrel portion facing said panel, said methodincluding driving said female element body portion shoulder into saidpanel portion, entrapping said panel portion between said body portionshoulder and said radially deformed barrel portion free end.
 5. Themethod of attaching a female element to a panel as defined in claim 1,characterized in that said die member includes a separate projectingcenter post surrounded by said die cavity, said center post having anaxial bore coaxially aligned with said punch piercing end and said diemember including biasing means resiliently biasing said center posttoward said panel, said method including ejecting said panel slug intosaid die post bore when said post is located adjacent said panel, thensaid panel portion resiliently biasing said center post into said diecavity as said panel portion is deformed into said die cavity to receivesaid barrel portion free end internal surface, said post then deformingsaid barrel portion radially outwardly into said die cavity.
 6. Themethod of attaching a female element to a panel as defined in claim 5,including ejecting said panel slug into said center post bore underpneumatic pressure.
 7. The method of attaching a female element to apanel as defined in claim 1, characterized in that said punch piercingend comprising a generally cylindrical piercing portion extendingaxially from said drawing portion, said drawing portion comprising arelatively smooth generally hemispherical surface increasing in diameterfrom said generally cylindrical piercing portion, said method includingpiercing said generally cylindrical piercing portion through saidunsupported generally cone-shaped panel portion, then driving saidgenerally hemispherical drawing surface against said panel portion toenlarge said panel opening and draw said panel into said die cavity,then driving said drawing surface through said panel opening, and thendriving said female element barrel portion against said panel portionand through said panel portion opening.
 8. The method of attaching afemale element to a panel as defined in claim 7, wherein said femaleelement barrel portion free end includes an arcuate external surface,said method including biasing said barrel portion free end against saidcone-shaped panel portion spaced radially from said punch under apredetermined load prior to piercing said panel portion and maintainingsaid predetermined load as said punch free end is driven through saidpanel opening.
 9. A method of attaching a female element to aplastically deformable panel, said female element including a bodyportion having a bore therethrough and an integral annular barrelportion generally concentric with said body portion bore andcommunicating therewith, said barrel portion having inner and outersurfaces and a free open end, said method comprising the following stepsperformed in a generally continuous operation:(a) locating and aligningsaid female element opposite a panel supported on a panel supportingsurface of a die member having a concave die cavity surrounding aprojecting center die post coaxially aligned with said female elementbarrel portion, said die post telescopically received through a bore insaid die member and said die post having an axial bore, a free end and aconcave radially outwardly extending die surface spaced from said diepost free end and said die member including a biasing means resilientlybiasing said die post toward said panel supporting surface; (b) drivinga free end of a punch through said female element body portion bore andsaid annular barrel portion into engagement with said panel, said punchdriving said panel into said die cavity and forming an unsupportedgenerally cone-shaped panel portion in said die cavity, further drivingsaid punch into said panel portion piercing a slug from generally thecenter of said unsupported generally cone-shaped panel portion andforming a pierced panel opening, ejecting said panel slug into said diemember center die post bore when said post is located adjacent saidpanel, then driving said female element barrel portion free end intosaid cone-shaped panel portion and through said pierced panel openinginto said cavity and against said radially outwardly extending diesurface of said die post driving said die post into said die cavity,said die member including a stop means preventing further telescopicmovement of said die post when said concave radially outwardly extendingdie surface is located near an adjacent die surface of said die cavity;and (c) driving said barrel portion free end against said concaveradially outwardly extending die surface of said die post radiallydeforming said barrel portion free end into said die cavity and forminga mechanical interlock with said panel portion.
 10. The method ofattaching a female element to a panel as defined in claim 9characterized in that said punch free end includes an axially extendingpiercing end followed by an enlarged convex drawing portion, said methodincluding driving said punch piercing end into said unsupported panelportion piercing a slug from said unsupported generally cone-shapedpanel portion, then driving said punch drawing surface through saidpanel opening, enlarging said panel opening and further driving saidpanel portion into said die cavity.
 11. The method of attaching a femaleelement to a panel as defined in claim 10, wherein said method includesdriving said female element barrel portion free end following drivingsaid punch through said panel opening, said barrel portion externalsurface drawing said panel portion into a tubular shape in engagementwith said barrel portion external surface, then plastically deformingsaid barrel portion free end radially outwardly to form a mechanicalinterlock with the free end of said tubular panel portion.
 12. Themethod of attaching a female element to a panel as defined in claim 9,including biasing said barrel portion free end against said panelportion spaced radially from said punch under a predetermined load priorto piercing said panel portion and maintaining said predetermined loadas said punch is pierced through said panel.
 13. The method of attachinga female element to a panel as defined in claim 9, including drivingsaid female element body portion into the developing tubular panelportion as said barrel portion free end is deformed radially outwardlyforming a flush mounted female element and panel assembly.